Car-wheel molding and casting flask.



A. GORDINGLY.

c111 WHEEL MOLDING AND (ms'rme FLASK.

APPLICATION FILED HA3. 4, 1911.

1,003,709. Patented Sept. 19,1911.

3 SHEETS-SHEET 1.

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A. GORDINGLY.

San/5 OAR WHEEL MOLDING AND CASTING FLABK.

. LPPLIOATIOR YILED All. 4, 1911. 1,003,709.

a alums-sum: 3.

A; GORDING LY. OAR WHEEL MOLDING AND GASTING FLABK.

I APPLICATION FILED KAI-'4, 1911.

Patented Sept. 19

' STATESTATENT c arion. f

1 'an' rann copnrnemgor nnnv'nn, coLoaano;

.. permit: one

- i-'cmw a mornmc nnn 'cas'rme rmsm,

To all whom it may concern:

v Be it-known that I, Atrium) ConnmqLY, a citizen-of the United States of Amenca,

fication.

My invention relates .to improvements in car wheel molding and casting flasks, and

the objects ofimy inventionare: Firstto provide a sectional molding flask, the parts of -wh1ch =.will accurately center themselves the flask is handled, and that is adapted to make a mold that will castany kind or character of a wheel accurately and that will permit wheels to be accurately duplicated; in any desired number. Secondto provide a wheel moldi flask that will one molder in one part. of a foundry, and

the ether part of the mold to be inade by.

another. mojlder in another part of a foundry or. at a distance'from and independent ofthe molder molding the first part, and that is so'arranged that ;-.the:tWO parts of the molded flask. can be-'quicklyput together, and so arranged that the cover pieces of the pattern are accurately and quickly-centered; and third-to provide a i two-part. wheel'molding and casting flask that is provided with a tread chilling ring portion that is removable from the cope or flippersectionof the flask when cracked or warped-1 or .-..otherwise worn out of proper form and is arranged to permit a new tread chilling ring to be replaced on the cope and thus prevent the throwing away of the whole cope or top section. when a chilling ring is worn out. I I attain these objects by'the mechanism illustrated in the accompanying drawings, in which: v y

I Figure 1 is a plan view .of the n'owel ring with the wheel pattern therein. Fig. 2 is a" central, vertical, sectional view through.

the nowel ring and wheejl pattern, showing sand which has been tamped in the ring and around the pattern to form the lower half of the mold. "Fig.'3 is a perspective view, showing the nowel ring in a reversed position to that shown in Figs. 1 and 2,

the; wheel pattern having been withdrawn from the sand, leaving the completed lower hal t of the-molds Fig. at is a vertical, secpart ofra wheegto be made by I v Specification o! act remnant; P t t Sept 1911! Application filed March '1, 1911. serial 110. 612,302. y

y which tern being filled with sand which surrounds hub pattern and a pouring core which rests .upon the hub. attern. Fig. 5 is a side ele "nowel ring, these parts being clamped-to gether by the usual clamping hooks. Fig: -6 1s a vertical, sectional view through the receive the molten metal. Fig. 7 is a plan -Fig. 8 is a plan viewof the ga e for cen- ,-terin the core which forms the ore of the hub. 1

-lar parts throughout the several-views.

Referring to the drawings, the numeral .1 designates the settin plate of my im- T proved mold. This settmg plate comprises any suitable fiat smooth ,to ped late of i. wood or metal, the bottom ot whic is pro vided with ribs 2, in order to strengthen and keep it from working'as well as to raise ts top surface far enough abovethe bottoms of the ribs to enable a: 'molder to 19.06 his hands under it and lift it around. pon this sett-in plate I lay the wheel pattern, which is ivided into two parts, the hub '3 and spokes 4, which are made in one attern,. and the tread 5 and'fia-nge 6, w ich in the form of a ring, into which the spokes 'and hub fit. The tread portion 5 is preferably made of wood, although if desired it may be made of any other suitablematerial, and the flange 6 is preferably made of cast iron but it may be made of any other suitable metal or material. The tread 5 is referably built up of three layers of boar s, each layer being formed of pieces of boards secured together, with the grain to the grain of the other ieces. This rin pattern is machine finishe on its inside an top surfaces, and on top of this ring attern I place a ring 7, which I term the rag ,or nowel ring. This drag or nowel ring is made of cast iron. This nowel or drag ring comprises a ring band portion 8, rovided with enlarged flanges 9 and 10 at t e opposite ends of the band portion, and it is provided with four upwardly-projecting lugs v vation of the ask comprising the cope-and Similar letters of reference refer to simi are made in a separate pattern, which is.

the upper part of the master pattern, a

' flask showing the completed mold ready to Eview on a reduced scale of the cope; and

of each piece arranged at a different angle .9, although more or less can be used ifde r sired. Both-the upper and lower faces of this drag ring are machined flat and smooth across to'the lugs. The inner faces are also machined by being 'bored to a' predetermined size that is adapted .to fit thelower edge of the cope or upper part of the mold, ained more fully hereinafter.

exactly concentric with the drag or nowel ring. The drag ring is then filled with sand, which is tamped between the spokes around the hub and over the pattern up even with the top of the drag ring, in' an operative molding manner. This drag ring,

the flange ring of the wheel pattern, and the setting plate I term the lower part of my improved double wheel molding flask.

This lower half of the flask with the wheel pattern still molded up within it is then turned upsidedown and is placed on top of a cast iron ring plate 11, which I term the bottom plate, the plate 11 havingfirst been placed upon the top of the drag ring to hold the sand within the same.

e The separate ring flange part 6 of the wheel pattern is then drawn from the mold,

and afterward the hub and spokes are with- I drawn from the mold, leaving the drag ring on the plate with the moldof the wheel built up above it, as shown in Fig. 3, in which thehub space 12 and spoke spaces 13 and the wall that forms the inner peripheral wall of the wheelare shown. This completes what I term the lower half of the mold. The perforated ring plate upon which the drag ring rests conslsts of a ring shaped lower ring portion 14, that rests on the ground or floor of the foundry and a flat plate portion 15 that is formed on one end of the ring portion and is preferably of enough larger diameter to form a lifting a and clamping edge portion around it for section of m the hands of an operator and the ends of the clamping 'dogs It}. This plate is of the same or about the same size of the flange ends of the drag ring. This lower part or improved two-part wheel casting. flask is as illustrated in an opera;- tive molded condition, and is ready for the cope or upper section portion of the mold, which is provided with a mold of a pattern 17, which I term a master wheel. This mas- 'ter wheel pattern is made of cast iron and is partially machine finished, as will be dethe.1am... a at. -..1....1

.comprises a hollow base ring portion 18,.

which is'p 19. This ase ring portion is rovided with op a. top ange portion 21 over the top ed e plate portion and on the sides of they .base' ring guide centerin lugs 22are formed. These lugs are place at equidistances apart and as many ma'yvbe used as desired. I

preferably use four .ofthese lugs, and they are arranged to extend vertically upward, above thetop plate a-sfew :inches, "and the inner surfaces are bored .outconcentrically with the axial center of the disk portionof the master pattern and they are tapered;

divergingly outwardfromthe top plate to" the. upper ends sufiicientlyto give, a clearance space or an enlarged diameter between plate portion 20, whic' projects in rovided -withf'a base edge flange of the ring. At the outer edges of -t e them at their up er ends of about from three-eighths to a alf inch. This tapering clearance. space between the-lugs is proor top section of the flask 23 to e'nterloosely, between the lugs and center. as it is lowered into bearin lugs at their junction withflthe machined surface of the master pattern.

' From the center of the top plate and base ,ring a round disk portion 24 projects upis to be cast andthe peripheral edge of this disk forms the outer wall of the molds boundary or the outer peripheral wallof the wheel that is-to be cast.

' A slight circular depression is formed in thetop surface of the disk portion of the master wheel pattern, which leaves a slightly raised top rim flange 25 on the top peripheral edge of the disk.

A short center pin 26 is formed in the axial center of the top of the disk portion of themaster wheel which enters the center-- ing pin aperture 27 of a pattern 27 of the,

contact with the bore of the ward a distance equal to the width of the vtread portion of the flange of the wheel that vided to permit the lower edge jof the cope hub portion'of a wheel, while the base portion of the hub'rests' loosely on the top surface of the wheel. This hub pattern may be of any size or, len th. The top surface also and the vertical side of the disk, as well as the top of the plate port-ion of the base ring,

is also machine finishedup to and against the centering lugs. This master pattern is used to produce the mold of the outer portion of the hub of the wheel and a portion of the tread and to center this hub' in the' .center of the chill surface of the cope or,

upper section 23, and it is used as follows: This master pattern is positioned in a level position on a suitabletable or bench or on the floor, and the top cope or upper section I of the mold is placed over it. This cope or top section 23 contains in its construction J and arrangement one of the most essential features of my invention. This cope or upper part of the flask comprises a round ringshap'ed casting 29 that contains two elements, one of which is a central cylindrical sleeve portion 30 that is ositioned in the center of the ring by radia arms 31 that extend from the inner peripheral wall of the ring to this cylindrical sleeve portion and which, together with the cylindrical sleeve, are cast integral with the ring shaped shell 29 of the cope. This cylindrical sleeve extends from the upper end of the cope to a little morethan one-half of the length of the cope, and a slot 32 is cut vertically through one side of its entire length to allow it to expand freely, and at the opposite or bottom end of the cope a chill ring portion 33 is secured.

The ring 29 is formed with oppositely po sitioned lugs 34 having bolt apertures, and the chill ring 33 is formed with similar apertured lugs 35, which are adapted to register with the lugs 34, and bolts 35- are passed through these lugs and secure the rings 29 and 33 together. The inner face of the ring 33 is machine finished, and its lower edge is recessed, as shown at 36, to match a recess 37 made by pattern part G'in. the other half ofthe mold, which together form the outline of the flange of the wheel.

The upper edge of the cope shell is provided with a horizontally arranged flange 38, and the lower end of the chill ring is machine finished and turned to fit against the inside surfacesof the lugs 22 and 9 respectively, when this cope is placed upon either the master pattern or the nowel ring.

It is necessary to lower the cope on the master pattern in order to mold the hub and arrange the upper part of the cope to match the mold of the lower part. Consequently, having set and leveled the master pattern in aposition where a molder can work around it, the cope is raised by hand if itis small and light or by a chain hoist if it is too heavy, the opposite sides of the cope being provided with trunnions 39 or handles by which the cope may be handled. These trunnions are positioned to permit the cope to be turned over upside down when suspended by chains, so as to bring the lower edge of the chill ring and of the cope uppermost and the top end of the cope down. This permits the molder to work off and 5 otherwise dressthe side and end surfaces of the chill ring and to clean off-the lower edge of the cope so that it will rest down tightly on the top plate of the master pattern. The

molder, having cleaned these surfaces, turns 0 the cope again right side up and then lowers it over'the master pattern and down onto its top plate between its lugs 22, between which it fits with a bearing fit which centers the cap accurately and concentrically on 5 the master pattern.

,40, as shown in Fig. a true vertical position by means of a gage 'stick 47, as shown in Fig. 1, the said gage The molder then places the hub pattern 27 down through the cylindrical sleeve onto the center of the master pattern, providing he did not do so beore placing the cope on the master pattern, and then sets a core 40 on the hub pattern, which core is of slightly reater diameter than the hub pattern an of a thickness to extend to the top of the ring 29, and having done this he fills and tamps the cylindrical sleeve with sand even to the top of the core 40, and also fills and tamps the spaces with sand between the outside of the cylindrical sleeve and the ring 29.

The core comprises a circular block of sand baked as is usual in formin cores for molding, and this block is, provided with a plurality of apertures 41, which are of a size to allow liquid iron to flow readily through them. A pouring guide ring 42 is then placed on the plate and the cope is filled with sand and tamped even with its.

top edge in the usual molding manner.

The disk portion of the master pattern is arranged to extend to and close enough the inner side surface of the chill against the cope so that when the top of ring oi the cope is filled with sand it cannot .flow

between the sideof the disk and the'side wall, of the chill ring.

The diameter of the chill ring 'is of a. size to form the tread surface of the wheel when cast, and it is arranged to form 'the tread and flange portionsof the wheel to be cast of the desired thickness when placed on the lower part of the mold that is held by the drag ring where it is arranged in such relative relation to the wall of the lower mold as to allow of tread and flange portion of a wheel of the desiredthickness to be cast, as will be more fully described hereinafter. The cope is then raised up from the master pattern and turned upside down again and the hub pattern which lifts from the master pattern with it is removed from it. leaving the mold of the hub' in the cope. The side and end surfaces and lower edge of the cope are again cleaned and the cope or upper section of the flask is ready to be lowered onto the lower section, which is molded in the drag or nowel ring.

Before lowering the cope upon the nowel ring, which holds the other part of the mold,

a core 43 which is adapted to form the bore of the hub is placed centrally in the hub opening. 12 of the first half of the mold and rests in a recess 44 formed by a projection 45 on the hub pattern 3, as shown in Fig. 2. This core extends above the mold and has a centering pin or projection adapted to enter a centering aperture in the block 6. This core is given corresponding in length to the distance bein bearing contact with cope, and the master tering lugs 9 and the periphery of the said co-re,. when the same is in 'atrue vertical gage successively core, the core is thereby given a true vertical position. Y

The inside diameter of the lugs of the master pattern and of the drag ring are of-exactly the same size. Consequently, the lower end of the chill ring of the cope fits the inside surface of the lugs of the drag ring and down against its turned fiat top surface 9, and the cope is accurately centered by means of the concentrically bored lugs and the machined surfaces of the drag ring and of the the mold of the hub and the bottom of the mold of the cope so that it fits on and is centered accurately on the mold of the'lower half or drag ring part of the mold? cope and drag ring are then clamped by the hooked dog rods 16 by wedges, and the flask [and mold is ready to pour, which is done by pouring the hot metal in the guide pouring ring onto the core block 40, from which the hot metal flows through the apertures llin this block into the hub space in the mold and-into the spoke spaces and into the circumferential space betweennthe Wall-ref the 1 lower section of the mold and the, side and end surfaces of the chill ring of the cope or upper section of the mold, which fills and forms the tread and flange portion of the wheel, thus completing the molding of. a wheel that is accurately round andperf'ctly formed in all of its parts. I

I have found in practice that in using a. cope having the chill ring cast integral with the hub molding portion of the cope that the great heat to which the chill ring is subjected by the contact of the hot metal directly with it at eachl'cast causes it to commence to check soon after a new ring cope is used, and this checking develops into cracks'with roughened up edge portions that develop into an open crack and rupture of the ring and necessitates the throwing away of the cope and the replacing of it by an entirely new one. This is expensive, as the new cope and its chill ring have to be machine finished and accurately fitted to the lugs of the master pattern and of the drag ring,

and my present invention contemplates a cope divided into two detachably connected parts, the top part of which is made of a length to carry the whole of the cylindrical hub receiving sleeve and its spokes, and the other is made of a length to carry the whole of the chill rin portion of the cope. These two separately made parts of my invention may be secured together by any suitable means for detachably connecting them together.' I preferably carry out this fea- .ture of my invention by casting the radially and.- the lower and perip pattern has arranged projecting lug portions/34 and 35 at equimeeting surfaces, as well asthe surfacesgofz the meeting edgeszof; the: two L parts, of

p andarigidly; 1

f'th s' gether'and-then-mach he chill ring part of. the'copefafte are securely bolted"together. I aring is worn-out it "can b removed from the top part ofthe cope and a..new.chiIl-Iring part can be attached to the top part ofi thejzf cope, as the'top part of the cope fwillj'ila'st" until accidentally broken. This featufidf;

my invention .efl'ects zaggreat, saving liiri-the cost of "keeping up, these specially con: strucfed and arranged flas The commonly used iron is provided with ears onv the drag perforation an'd "an "car on the cops part provided with around The pins and holes soon wea-ruloosev and leave a loose con nection between the two parts of the flask,

part containing a as their meeting edges are narrow and un finished and provide a flask wholly-inserted to themolding of wheelsiof accurate size and form in large,number,.and-with such "a fia'sk it would be impossible for two differ ent workmen to prepare the molds so that they would go quickly together in such ac- .curate relation as to mold'wheels of the same size. My flask, on the other hand, can be handled roughly and quickly in putting in all of these operations of molding and putting together, and their parts always come accurately to a common center.

My invention is simple but permits anydesired number of any size or shape to be made by making a drag ring, a master pat-' tern, and a cope embodying the features of my invention, and the most valuable feature in connection with my improved flask is that it permits of one molder in one part of a foundry to make up any desired number of the lower or drag'ring parts of the mold and another molder to mold up from the master pattern the same number of the upper parts of the pattern in the cope with the assurance that the parts thus separately made up by different molders will fit accurately and concentricallytogether.

Another feature of my invention of value is that when it is desired to cast the hub with an axialaperture through it, the core 43 can be accurately centered from the four machine bored lugs of the drag ring by the gage stick 47. or by ,a rule, by applying it successively to the opposite lugs and moving the core until it stands in the center of the hub aperture of the mold.

My invention is simple and a great labor saver in the continuous production of cast car or other wheels in'large numbers of accurate form and size, and, while I have portions on said lower section having tapered inner faces with which said upper section and said chill-plate engage and by means of which the parts are maintained in proper relation.

3. A flask comprising upper and lower mold-sections, a divided sleeve within said upper section, radial arms connecting the wall of said upper section and said sleeve, and ro ecting portlons on said lower section or maintaining said sections in proper relation.

4. A flask comprising upper and lower mold-sections, a chill-plate detachably secured to said upper section, and upwardly projecting portions on said lower section having tapered inner faces with which said upper section and said chill-plate engage and by means of which the parts are maintained in proper relation.

5. A cope comprising a ring having detachably secured thereto a chill-ring, the peripheral portions of said rings being of the same diameter.

6. A flask comprising a lower section having upwardly projecting portions with tapered inner faces, and an upper section or cope comprising a ring having detachably secured thereto a chill-ringy'the peripheral portion of said rings being of the same diameter and adapted to engage the inner faces of the projecting portions of the lower section.

7. A car-wheel mold having a lower sec-- tion comprising an outer ring having upwardly projecting portions with tapered innor faces and containing sand molded to form the spokes and portions of the rim, flange, and hub; and a separate upper section, comprising an outer ring having detachably secured thereto a chill-ring, seated within the upwardly projecting portions of the lower section, said upper section having sand molded therein with surfaces cooperating with those of the upper section to complete the wheel.

8. A flask comprising a drag-ring, upwardly projecting portions on said dragrln vidlng \vitlffsaid drag -ring an annular shoulder, and a separate upper section having a chill-ring detachably secured thereto and adapted to seat on said shoulder.

9. A flask comprising a drag-ring, upwardly projecting portions ring having tapered inner fares and providing with said dragring an annular shoulder, and a cope comprising a ring having achill-ring detachably secured thereto, the peripheral portions of said cope and chill-rings being of the same diameter, said chill-ring being adapted to seat on said annular shoulder.

In. testimony whereof I atlix my signature in presence of two witnesses.

' ALFRED CORDINGLY.

Witnesses:

G. SARGENT ELLIO'I'I, ADELLA M. FOWLE.

having tapered inner faces and pro on said drag- 

